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Abstract:

A recessed ceiling light fixture with spring biased retainer clips that
retract flush or are biased away from the side of the can housing for
installation is disclosed. The fixture includes a housing having a side
wall, a top wall, and an open bottom. Two rigid retainer clips are
mounted diametrically opposed on the housing. Each retainer clip has a
mounting tab inside the housing extending into a leg that passes out of
the housing, which leg is bent to form an elbow, which elbow extends to a
strut passing back into the housing, wherein the mounting tab selectively
engages the side wall to limit movement of the spring clip. A bolt and
coiled spring create compliance and bias in the spring clip by passing
loosely through a slotted opening in the top wall at one end and joining
the mounting tab at the other end.

Claims:

1. A recessed ceiling light fixture, comprising: a housing having a side
wall, a top wall up on top, and an open bottom with a lip at the bottom;
a plurality of openings in the side wall; at least one rigid retainer
clip having a mounting tab inside the housing extending into a leg that
passes through one of the openings out of the housing, which leg is bent
at a distal end to form an elbow, which elbow extends to a strut passing
through one of the openings into the housing, wherein the mounting tab
selectively engages an interior of the side wall; means for creating
compliance extending loosely through a slotted opening in the top wall
and connecting to the mounting tab, wherein the means for creating
compliance simultaneously biases the leg to swing away from the side wall
and downward toward the open bottom; and wherein the leg swing away from
the side wall under spring bias is limited by at least one of the
mounting tab engaging the side wall and the means for creating compliance
engaging a lip of the slotted opening in the top wall.

2. The recessed ceiling light fixture of claim 1, wherein rigid retainer
clip has a rigidity to support the weight of the recessed ceiling light
fixture with minimal flexing.

3. The recessed ceiling light fixture of claim 1, wherein the leg
includes a plank shape with a rib extending along a length thereof.

4. The recessed ceiling light fixture of claim 1, wherein the means for
creating compliance includes a bolt and a coiled spring disposed around
the shaft of the bolt, and wherein the bolt passes loosely through the
slotted opening in the top wall at one end and is attached to the
mounting tab at an opposite end.

5. The recessed ceiling light fixture of claim 4, wherein the bolt
includes a bolt head at one end disposed outside of the housing and
threads at an opposite end screwed into the mounting tab, and turning the
bolt head changes the distance between the mounting tab and the top wall
thereby changing the amount of force on the spring.

6. The recessed ceiling light fixture of claim 1, wherein the means for
creating compliance includes a shaft extending from the mounting tab and
passing loosely through the slotted opening in the top wall, and wherein
a spring is disposed with the shaft to press against the top wall and the
mounting tab.

7. The recessed ceiling light fixture of claim 1, wherein a distal end of
the strut includes at least one of a hook, a bend, a T-shaped tip, and a
tab having a hole therethrough.

8. The recessed ceiling light fixture of claim 1, wherein the interior of
the housing includes mounting hardware.

9. The recessed ceiling light fixture of claim 1, wherein the plurality
of openings in the side wall are T-shaped.

10. A recessed ceiling light fixture, comprising: a cylindrical housing
having a side wall, a top wall up on top, and an open bottom with a lip
at the bottom; a plurality of openings in the side wall; two retainer
clips mounted diametrically opposed on the housing, each retainer clip
having a mounting tab inside the housing extending into a leg that passes
through one of the openings out of the housing, which leg is bent at a
distal end to form an elbow, which elbow extends to a strut, wherein the
mounting tab selectively engages an interior of the side wall; means for
creating compliance passing loosely through a slotted opening in the top
wall and joined to the retainer clip via the mounting tab, wherein the
means for creating compliance simultaneously biases the leg to swing away
from the side wall, and to translate the leg downward toward the open
bottom; and wherein the leg swing motion away from the side wall is
limited at least by the mounting tab bumping into the side wall.

11. The recessed ceiling light fixture of claim 10, wherein the means for
creating compliance includes a bolt and a coiled spring disposed on the
shaft of the bolt, and wherein the bolt passes loosely through the
slotted opening in the top wall at one end and is attached to the
mounting tab at an opposite end, and the spring is compressed
therebetween, and wherein the bolt shaft freely pivots along the slot and
translates through the slotted opening.

12. The recessed ceiling light fixture of claim 10, wherein a distal end
of the strut passes through one of the openings into the housing, and the
distal end further includes at least one of a hook, a bend, a T-shaped
tip, and a tab having a hole therethrough.

13. The recessed ceiling light fixture of claim 11, wherein the slotted
opening in top wall enables the bolt to freely swivel along the direction
of the slot and to freely translate through the slot thereby creating
compliance in the spring clip.

14. A recessed ceiling light fixture, comprising: a can shaped housing
having a side wall, a top wall, and an open bottom with a lip at the
bottom; a plurality of slots in the side wall; a plurality of retainer
clips, each retainer clip having a mounting tab inside the housing
extending into a leg that passes through one of the slots out of the
housing, which leg is bent at a distal end to form an elbow, which elbow
extends to a strut passing through one of the slots into the housing,
wherein the mounting tab selectively engages an interior of the side
wall; means for creating compliance passing loosely through an oversized
opening in the top wall and connected to the mounting tab, wherein the
means for creating compliance enables the retainer clip to have at most
two degrees of freedom in movement of each leg; and wherein one of the
degrees of freedom in the leg movement includes biasing the leg to pivot
away from the side wall of the housing, which pivoting movement causes
movement of the mounting tab and means for creating compliance such that
at least one of the mounting tab and means for creating compliance
selectively engages the side wall and top wall, respectively, thereby
limiting the pivoting movement of the leg.

15. The recessed ceiling light fixture of claim 14, wherein the means for
creating compliance includes a bolt having a bolt head at one end
disposed outside of the housing and threads at an opposite end screwed
into the mounting tab, and a spring disposed on the bolt, so turning the
bolt head changes the distance between the mounting tab and the top wall
thereby changing the amount of compression on the spring.

16. The recessed ceiling light fixture of claim 14, wherein the mounting
tab includes a protruding surface that selectively engages the side wall
to limit the pivoting movement of the leg.

17. The recessed ceiling light fixture of claim 16, wherein mounting tab
includes a C shape with the top of the C receiving the threaded end of
the bolt, and the bottom of the C having the protruding surface that
selective engages the side wall to thereby limit the pivoting movement of
the leg.

18. The recessed ceiling light fixture of claim 14, wherein the strut at
a distal end thereof inside the housing includes a tip bent toward the
open bottom.

19. The recessed ceiling light fixture of claim 14, wherein another of
the two degrees of freedom includes linear translation of the leg under
bias downward relative to the housing top and bottom, and wherein the
means for creating compliance creates bias in the leg pivot and the bias
in the leg translation simultaneously.

20. The recessed ceiling light fixture of claim 14, wherein the mounting
tab, leg, elbow, and strut are formed in one integral piece of material
for rigidity.

Description:

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This application claims priority from U.S. provisional application
no. 61/329,501, filed Apr. 29, 2010, which is hereby incorporated by
reference in its entirety.

BACKGROUND

[0002] Light fixtures recessed into the ceiling are popular in residential
homes and commercial buildings. Recessed lighting fixtures provide a
flush, aesthetic appearance that is attractive to many because the design
hides the electrical hardware and wiring inside a space behind the
ceiling. Typically, the light fixture comes in the form of a housing
shaped like a can, and a light source with a reflective trim fitted
inside the can. Wiring is fed into the can to power the light source.
Mounting hardware attaches the can to the building frame, ceiling joists,
or ceiling support structure.

[0003] There have been different attempts at mounting the ceiling light
fixture. Examples include U.S. Pat. No. 4,293,895 (Krisofek), U.S. Pat.
No. 4,733,339 (Kelsall), U.S. Pat. No. 5,377,088 (Lecluze), U.S. Pat. No.
5,609,414 (Calouri), U.S. Pat. No. 6,174,076 (Petrakis), U.S. Pat. No.
6,554,458 (Benghozi), U.S. Pat. No. 6,827,471 (Benghozi), U.S. Pat. No.
6,896,394 (Houle), U.S. Pat. No. 7,331,555 (St-Pierre), U.S. Pat. No.
7,530,717 (Magisano), U.S. Pat. No. 7,549,780 (Calouri), U.S. Pat. No.
7,618,167 (Bedard), and U.S. Patent Application Publication No.
2009/0010007 (Calouri), generally directed to recessed lighting fixtures
where legs or similar structures extend from the can to mount the fixture
into the ceiling space.

SUMMARY OF THE INVENTION

[0004] The present invention in various preferred embodiments is directed
to a recessed ceiling light fixture comprising a housing having a side
wall, a top wall up on top, and an open bottom with a lip at the bottom,
a plurality of openings in the side wall, with preferably two rigid
retainer clips mounted circumferentially opposed to the housing. In the
preferred embodiment, each retainer clip has a mounting tab positioned
inside the housing, which mounting tab extends into a leg that passes
through one of the openings out of the housing, which leg is bent at a
distal end to form an elbow, which elbow extends to a strut passing
through one of the openings back into the housing. The mounting tab
selectively engages an interior of the side wall as it moves with the
retainer clip. A means for creating compliance extends loosely through a
slotted opening in the top wall and connects to the mounting tab, wherein
the means for creating compliance simultaneously biases the leg to swing
away from the side wall and downward toward the open bottom.

[0005] The leg swing away from the side wall under spring bias is limited
by at least one of the mounting tab engaging the side wall and the means
for creating compliance engaging a lip of the slotted opening in the top
wall. Preferably, the means for creating compliance is a threaded bolt,
wherein the bolt head is outside of the housing and its shaft passes
through the slotted opening in the top wall into the housing where the
threaded end attaches to the mounting tab. The fitment of the bolt within
the slotted opening allows the bolt to swivel and pivot freely within the
slot and along the elongation of the slot. The bolt also free traverses
through the slotted opening. A coiled spring is preferably disposed on
the bolt shaft captured between the top wall and the mounting tab such
that there is some compression in the spring.

[0006] The loose fitment of the bolt through the slotted opening allows
the entire rigid retainer clip, specifically the leg, to pivot and swing
away or toward the housing, and the leg to translated up and down the
outside of the housing. Preferably, the spring simultaneously biases the
leg in a direction away from the housing and in a direction downward
toward the open bottom of the housing.

[0007] The rigid retainer clip exhibits a rigidity that supports the
weight of the recessed ceiling light fixture including internal
components, wiring, lamp, etc., with minimal flexing. Further, the distal
end of the strut may include a hook, a bend, a T-shaped tip, and/or a tab
having a hole therethrough. Each of these structures provides a finger or
thumb accessible contact surface. The tab with a hole allows a
screwdriver tip to pass through. An installer or electrician can thus
reach into the housing and use his or her finger or thumb on one hand to
hold the opposed retainer clips, apply closing pressure to retract the
retainer clips against the spring bias. This pressure moves the legs
radially inward, retracting the legs relatively, substantially flush
against the exterior of the housing. In this state, the fixture can be
easily pushed through the cut out in the ceiling. Once passed through,
the finger pressure is release allowing the retainer clips to rebound
radially outward, thus deploying the spring clips and specifically
placing the extended elbows in position. The fixture can now rest on the
deployed spring clips.

[0009] FIG. 2 is a perspective view of the FIG. 1 embodiment with the
junction box removed to expose the wiring extending into the can housing.

[0010]FIG. 3 is a perspective view of the FIG. 1 embodiment, as seen from
beneath or in front of a ceiling panel, wherein the can housing assembly
is about to be inserted through a cutout in the ceiling panel and the
retainer clips are moved to a retracted condition.

[0011]FIG. 4 is the can housing assembly passing through the ceiling
cutout.

[0012] FIG. 5 is the can housing assembly fully inserted through the
ceiling cutout, as seen from above or behind the ceiling panel, with the
retainer clips beginning to deploy radially outward.

[0013] FIG. 6 is the can housing assembly with the retainer clips fully
extended and supporting the weight of the can housing assembly while
resting on the ceiling panel.

[0014] FIGS. 7(a)-7(c) are various perspective views of a preferred
embodiment retainer clip used with a can housing assembly.

[0015] FIG. 8 is a side elevational cutaway view of the embodiment shown
in FIG. 7.

[0016] FIGS. 9(a)-9(d) are various views of the retainer clip from the
embodiment shown in FIG. 7.

[0017] FIG. 10 is a perspective view of an alternative embodiment retainer
clip used with a can housing assembly.

[0019] FIG. 12 is a side elevational view of a preferred embodiment can
housing

[0020] FIG. 13 is a perspective view of the can housing from FIG. 12.

[0021] FIGS. 14(a)-14(f) are various views of an alternative embodiment
can housing.

[0022] FIGS. 15(a)-15(b) are perspective views of a can housing assembly
with an alternative embodiment retainer clip.

[0023] FIG. 16 is a side elevational cutaway view of the embodiment shown
in FIG. 15.

[0024] FIGS. 17(a)-17(d) are various views of the alternative embodiment
retainer clip shown in FIG. 15.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] As seen in FIG. 1, the present invention is directed to a recessed
can housing assembly 10 with spring loaded retainer clips 12. In the
preferred embodiment shown, there are two retainer clips 12 arranged
diametrically opposed on the housing assembly 10. In various alternative
embodiments (not shown), there can be more or fewer retainer clips 12
depending on application, size and weight of the can housing assembly
with hardware, and shape of the housing. The can housing assembly 10 is
intended for installation into the ceiling such that the hardware is
recessed into the ceiling or ceiling panel and cannot be seen from the
front or bottom side. As such, the can housing is preferably cylindrical
in shape with a round top wall 18, an open bottom, and a cylindrical side
wall. Other shapes for the can housing such as an elongated box are
contemplated.

[0026] The can housing assembly 10 is intended to contain a lighting
fixture having a reflector, trim, lens, etc. and/or a light source (not
shown) such as an incandescent bulb, halogen bulb, a compact fluorescent
light (CFL), an LED cluster, and the like. Indeed, as seen in FIG. 8, one
or more brackets 56 disposed along the interior circumference of the can
housing assembly 10 are adapted to receive a trim ring (not shown) that
snaps into place. The trim ring in various embodiments can hold a
reflective trim and the light source, and the trim ring may be gimbaled
so the light from the light source can be aimed or adjusted. Power is
supplied to the light source via optional junction box 14 mounted to the
top of the can housing assembly 10. The junction box 14 provides a
holding chamber for the confluence of electrical wiring routed to the
light source inside the can housing assembly 10. The junction box 14 may
also hold driver electronics and support heat sinks, etc., if the light
source is an LED cluster.

[0027] In FIG. 2, the junction box 14 has been removed to show the
electrical wiring 16 routed to the can housing assembly 10. The
electrical wiring 16 passes through the top wall 18 of the can housing
assembly 10 and into the interior and connects to an electrical socket 58
(FIGS. 7(a), 8). The socket 58 is configured to receive a lighting
fixture or a light source (not shown) such as an incandescent light bulb,
a fluorescent lamp, a halogen lamp, an LED cluster, or the like.

[0028] As seen in FIG. 2, the open bottom of the can housing assembly 10
has an optional flange or lip 20. The lip 20 extends around the periphery
of the can housing bottom. The radially-outwardly extending lip 20 is
intended to help stabilize the housing after installation into the
ceiling space.

[0029] FIGS. 3-6 depict a sequence of events in the installation of the
can housing assembly 10 through an opening or cutout 22 in a ceiling
panel 24 or similar walled partition in a home or commercial office
building. FIG. 3 shows the can housing assembly 10 located underneath a
ceiling panel 24 being prepared for installation. Specifically, as
indicated by the arrows, the retainer clips 12 are pushed from the
outside of the housing radially inward and optionally pushed upward; or
simultaneously pulling the retainer clips radially inward and optionally
pushing them upward from the inside of the housing (described in more
detail below), to a retracted position so that the can housing assembly
10 can fit within the cutout 22 and be inserted into the round ceiling
cutout 22. FIG. 4 shows the insertion of the can housing assembly 10
through the cutout 22. FIG. 5 is a view from behind (or above) the
ceiling panel 24, wherein the retainer clips 12 have just cleared the
ceiling panel 24 and are about to translated linearly downward and deploy
radially outward as indicated by the arrows. FIG. 6 shows the retainer
clips 12 fully deployed radially outward and shifted downward toward the
ceiling panel 24. The ceiling panel 24 is now sandwiched between the lip
20 from the front of the ceiling panel 24 and the retainer clips 12 from
the behind the ceiling panel 24. The retainer clips 12 support the entire
weight of the recessed can assembly 10 and the clips 12 rest on the
ceiling panel 24 as shown. Accordingly, the recessed can assembly 10 can
be installed quickly and without need for any tools, fasteners, or extra
mounting hardware.

[0030] In fact, the retainer clips 12 can be pinched from the inside of
the housing assembly 10 with one hand, and with that same hand, the can
housing assembly 10 can be pushed through the cutout 22, then allow the
retainer clips 12 to deploy, all using only one hand. This is very
advantageous because the electrician or installer during installation
will be standing atop a ladder and working overhead on these ceiling
light fixtures. Thus, the one-hand installation is beneficial because it
frees the electrician's other hand to stabilize himself or herself on the
ladder, to hold a tool with the free hand, etc.

[0031] FIGS. 7-9 illustrate one preferred embodiment of the retainer clip
12. FIGS. 7(a)-(c) are perspective views showing how the retainer clips
12 are mounted to the can housing 52. In FIG. 7(a), it can be seen that
the retainer clip 12 has a mounting tab 30 that transitions into a leg 26
which then is bent inward to form an elbow 32. The elbow 32 as seen in
the side view of FIG. 8 may have a flat section, or may have a V-shaped
vertex without the flat section. The flat section provides move surface
area to reduce the stress when the light fixture is installed, which
stress if excessive might cause the elbow 32 to gouge and damage a
ceiling tile which in some applications is made from a soft or brittle
plaster.

[0032] The elbow 32 transitions into a strut 28 pointed inward toward the
center of the housing 52. An optional bent tip 40 at the distal end of
the strut 28 gives purchase for thumb and finger contact for
installation. In this preferred embodiment, the mounting tab 30 is
disposed inside the can housing 52. At least a portion of the leg 26
extends from the mounting tab 30 out through a slotted opening 46 in the
side wall of the housing 52 to the exterior. The strut 28 extends through
another slotted opening 50 in the side wall from the exterior to the
interior of the housing 52. The slotted openings 46, 50 are oversized and
shaped so that portions of the leg 26 and strut 28, respectively, can
freely move in and out without encountering too much or any frictional
drag from scraping the edge of the openings.

[0033] The mounting tab 30, leg 26, elbow 32, and strut 28 are preferably
made from a single piece of rigid material, such as steel. In order for
the retainer clip 12, and specifically the leg portion to translate and
swing as needed, even though the retainer clip itself needs to be
generally rigid to support the entire assembly 10, there is provided a
means for creating compliance. The means for creating compliance is
preferably fitted to the mounting tab 30 and attaches the retainer clip
12 to the can housing 52. Thus, the rigid portions of the retainer clip
12 (that is, mounting tab 30, leg 26, elbow 32, strut 28 all move as a
unitary structure) now have compliance as needed, and can move in several
directions or degrees of freedom. In the preferred embodiment, the rigid
portions of the retainer clip 12, and specifically the leg 26, can swing
radially inward or outward where the elbow 32 strikes an arc. Also, the
leg 26 can translate linearly up and down generally parallel to the side
wall of the can housing 52. These two movements can occur independently
or concurrently. The means for creating compliance further restricts the
movements to the two degrees of freedom so the string clips 12 do not jam
or encounter resistance when retracting or deploying.

[0034] As seen in FIG. 8, in the preferred embodiment, the means for
creating compliance includes a bolt fastener 42 and a coiled spring 44
disposed on the bolt shaft. The head of the bolt 42 extends through the
top wall 18 via a slotted opening. The opposite end of the bolt 42
preferably has threads that are screwed into the mounting tab 30.
Captured in the space between the top wall 18 and the mounting tab 30 is
the spring 44 which is placed in compression by the two structures.
Advancing the bolt 42 into the mounting tab decreases the space and
increases compression or stored energy in the spring 44. This reduces the
compliance in the system; unscrewing the bolt out of the mounting tab
increases compliance in the system. Reducing the compliance makes the
retracting the legs 26 more difficult as there is more spring bias felt
by the installer, and vice versa. Also, the slotted opening 48 (FIGS.
7(a), 13) that bolt 42 passes is an elongated hole, with the elongation
extending radially from the center of the can housing 52. This elongated,
oversized slotted opening 48 allows the bolt shaft to pivot or swing
freely, which allows the leg to swing out and back. This pivoting or
swinging action sequence of the bolt 42 can be best seen in comparing the
angle of the bolt shaft in FIGS. 5 and 6. In FIG. 5, because the bolt 42
swings out within the slotted opening 48, this allows the leg 26 to swing
freely inward to be relatively, substantially flush against the side wall
of the can housing 52. The spring 44 is compressed in this state. As
described above, the retraction of the legs 26 is accomplished under
thumb and finger pressure. Once the installation is complete, the legs 26
are released and under the bias of compressed spring 44, the legs 26 pop
radially outward. The bolt head, taking the opposite motion to the leg,
swing inward as seen in FIG. 6.

[0035] The oversized, elongated opening 48 further enables the bolt 44,
and by its physical connection, the entire spring clip 12 to translate
upward and downward relative to the can housing 52. This is depicted in
FIG. 5 where under thumb and finger pressure, the retainer clips 12 have
been pushed and translated upward relative to the housing 52. Thus, it
can be seen in FIG. 5 that the bolt head has moved a distance away from
the top of the top wall 18. The spring 44 is compressed in this state.
Once the finger and thumb pressure on the spring clips 12 is removed, the
spring clips 12 again under spring bias are urged downward toward the
open bottom of the can housing 52, as seen in FIG. 6. As a result, the
bolt heads have also moved a distance closer to the top of the top wall
18.

[0036] Thus, in the deployed state, the spring bias continuously urges the
legs 26 radially outward and downward as seen in FIG. 6. In the
retracting state, the swiveling/pivoting action and translating action of
the spring clips 12 described above can be achieved independently or can
occur simultaneously. The two motions of each spring clip 12 are
controlled by application of thumb and finger pressure of the installer.
This gives the installer the most control to manipulate and wiggle the
spring clips 12 into position for easy, quick installation, especially
when standing atop a step ladder and working above head level.

[0037] The means for creating compliance can take other forms. For
example, the coiled spring can be replaced with one or more bar springs.
The bolt 42 may be threaded into the mounting tab 30 as described, or the
bolt may be replaced by a shaft-like structure that is riveted, soldered,
spot welded, or similarly secured into place on the mounting tab. Or the
mounting tab, in one alternative embodiment, may have an extension
(replacing the bolt) that passes through the slotted opening 48 and
reciprocates and pivots as with the bolt. In yet another alternative
embodiment, the bolt and spring combination is replaced by a coiled
spring that is joined to the top wall 18 and the mounting tab 30 at
opposite ends. The coiled spring enables the mounting tab 30, and by
default due to its rigid structure, the retainer clip 12, to
reciprocate/translate and swing/pivot in and out.

[0038] As best seen in the perspective view of FIG. 9(a), the retainer
clip 12 in this preferred embodiment has a straight leg 26 with an
optional flute or rib 36 embossed or formed into the leg to increase its
rigidity. At the top of the leg 26 and preferably formed integrally with
the leg is the mounting tab 30 having a fastener eyelet 38 and a block 34
spaced away directly underneath. At the bottom of the leg 26 is a strut
28, and where the strut and leg meet is an elbow 32. All of these
components are preferably formed integrally, that is, formed from one
continuous piece of material. At the free distal end of the strut 28 is a
bent tip 40 for thumb/finger access by the installer or electrician. As
mentioned above, the finger access is used to pull the legs 26 radially
inward and to push the legs 26 upward from inside the housing 52. This
feature is used for installation, or when outside access to the legs 26
is not possible after the can housing assembly 10 has been installed into
the ceiling panel and replacement, repair or electrical work is desired.

[0039] As seen in the various views of FIGS. 9(a)-(d), the retainer clip
12 is formed from one piece of material, preferably a rigid steel strip
that is stamped and bent. Or the part may be cast. The optional flute 36
is stamped or formed into the leg 26 to ensure that very little
flexibility, bending, or twisting occurs in the leg in normal use because
it is a load bearing member. The eyelet 38 is optionally reinforced to
receive the bolt fastener 42 therethrough. In the side elevational view
of FIG. 9(c), the leg 26 intersects the mounting tab 30 at an obtuse
included angle while the leg 26 meets the strut 28 at the bottom forming
an acute included angle. The upper mounting tab 30 and lower block 34 are
generally parallel surfaces. The entire structure of the retainer clip 12
with the various bends is preferably very rigid with virtually no
flexibility under normal operating conditions.

[0040] This rigidity is used to offset the combined weight of the can
housing assembly, lamp or illumination source, electrical wiring, trim
ring, optional reflector, optional LED driver, other miscellaneous
hardware when installed in the ceiling space. The rigidity should be
sufficient to carry the combined weight without apparent flexing in the
spring clip, and remain stable when installed so that the entire unit
does not topple over from normal environmental conditions.

[0041] FIG. 8 is a side elevational cutaway view of the can housing
assembly 10. There are two retainer clips 12 shown, although more than
two retainer clips can be used. Each mounting tab 30 receives its
respective fastener 42, preferably a partially threaded bolt 42
therethrough. The shaft of the fastener 42 passes through a coiled spring
44. The threads of the fastener 42 are only at the end that screws into
the mounting tab 30; the shaft at the bolt head end does not have any
threads and has a smooth OD. This non-threaded shaft portion slides
freely through an enlarged, slotted opening 48 in the top wall 18, as
best seen in FIG. 7(a). In fact, in the upper view of the can housing 52,
the slotted opening 48 has an enlarge circular opening at one end of the
slot, which opening allows the head of the bolt 42 to pass through for
easy assembly or disassembly. The bolt 42 can thus be pre-assembled to
the mounting tab 30, and in one step, the bolt head can pass through the
enlarged opening. Disassembly requires on sliding the bolt head through
the slotted opening 48 to its enlarged end and pulling the bolt head
through. The bolt 42 itself never needs to be unscrewed from the mounting
tab 30, which reduces manufacturing and labor costs.

[0042] As seen in FIGS. 7-8, the retainer clip 12 thus has its mounting
tab 30 region located inside the hollow, cylindrical, can housing 52. The
top portion of the leg 26 extends from the mounting tab 30 out through an
upper slot 46 in the housing 52 to the exterior, and slopes downward. At
the bottom, the leg 26 is kinked inward at the elbow 32 leading to the
strut 28, which terminates at the bent tip 40. Strut 28 passes through
opening 50 as seen in FIG. 7(a). As each retainer clip 12 is deployed or
retracted (FIGS. 3-6), a length of strut 28 freely reciprocates through
slot 50. That is, there is preferably no or minimal contact between the
strut 28 and the edges of the opening 50 so as to avoid or minimize
friction or drag on the motion of the retainer clip 12. In this
embodiment, part of the strut 28 and the bent tip 40 always remain inside
the housing 52.

[0043] With this arrangement, the combination of the coiled spring 44 and
bolt movement within the slotted opening 48 introduces compliance into a
system which would otherwise be rigid. As such, the retainer clip 12 can
be translated linearly upward in FIG. 8 to compress the coiled spring 44
between the underside of the top wall 18 and the mounting tab 30, thus
pushing the bolt along its shaft such that the bolt head moves away from
the top wall 18. Further, the retainer clip 12 may be rocked or swiveled
from its position shown in FIG. 8 so that the previously outwardly flared
leg 26 is now essentially flush alongside the outer wall of the housing
52. This rocking/swiveling action wherein the leg 26 moves radially
inward is enabled by compressing the spring 44 and also by the head end
of the bolt 42 pivoting outward within the slot-shaped opening 48.

[0044] A combination of the linear translation and rocking actions of the
retainer clip 12 is shown FIG. 5 where the linear translation has lifted
the bolt head away from the top wall 18, and simultaneously pivoted the
bolt head away from the center of the housing 52. This process is used to
retract the legs 26 to move them substantially flush against the sides of
the housing 52 for installation. The actions act against the bias of the
coiled spring 44, which is now compressed.

[0045] In FIG. 6, the restraining finger pressure of the installer on the
retainer clips 12 has been removed. The now unopposed bias in the coiled
spring 44 acts to return the retainer clip 12 to its original start
position (FIGS. 7, 8) so that the retainer clip 12 has linearly
translated downward moving the bolt head into contact with the top wall
18, and rocking the bolt head toward the center of the housing 52 while
deploying the legs 26 radially outward (indicated by the arrows in FIG.
6). Once deployed, the legs 26 are used to support the can housing
assembly 10 upon the ceiling panel 24. The weight of the assembly is
supported at the elbow 32, and the bias in the coiled spring 44 creates
more pressure to squeeze the ceiling panel 24 sandwiched between the
elbow 32 and the lip 20. This creates a tight, quality fit between the
housing 52 and the ceiling panel 24.

[0046] If the can assembly 10 needs to be removed, the installer or
electrician can use his or her thumb/fingers to squeeze together the two
bent tips 40 of the respective retainer clips 12 and push the clips
upward. This radially inward pressure retracts the previously deployed
legs 26 inward moving them generally or mostly flush against the outer
wall of the housing 52 and the upward push removes the spring biasing
pressure acting on the ceiling panel 24. The can housing assembly 10 can
thus be pulled or dropped out of the ceiling cutout 22.

[0047] As seen in FIG. 8, the outward bias caused by the spring 44 never
causes the legs 26 to overextend to a degree where the bent tip 40
actually touches or engages the inner wall of the housing 52. Indeed,
FIG. 8 shows the full outer expansion of the legs 26. One mechanism in
the preferred embodiment to prevent the overextension is the block 34
underneath the mounting tab 30 in each retainer clip 12. Any outward bias
from the spring 44 with any momentum in the system caused by the outward
bias is opposed by the block 34. Specifically, the radially outward
rotational action of the leg 26 causes the block 34 to rotate radially
outward to a point where an optional edge 54 of the block 34 or some
portion of the block itself without the edge comes into contact with and
abuts the interior of the housing 52, and this contact completely stops
the radially outward travel of the leg 26. (The slight gap seen in FIG. 8
between the edge 54 of the block 34 and the inner wall of the housing 52
would be closed.) This is because the entire retainer clip structure is
fairly rigid (except for the spring), so any movement in one part of the
structure (i.e., the leg) translates to movement in another part of the
structure (i.e., the block). Conversely, blocking movement in one part
likewise blocks movement in another part. Further, after the can assembly
10 is installed and the legs 26 are deployed as in FIG. 8, the block 34
also stops the legs 26 from overly extending radially outward, which if
it were to happen would not create a tight fit between the housing 52 and
the ceiling panel 24.

[0048] Alternatively, the rocking action of the retainer clip 12 can be
limited by the elongated size of the slotted opening 48. As seen in FIGS.
5 and 6 and described earlier, the bolt head and bolt shaft pivot or
swivel along the longitudinal elongation of the opening 48. Thus, by
limiting the elongation size of the opening 48, the bolt shaft at its
pivot extremes engages the opposite edges of the slotted opening and can
pivot no farther, as in FIGS. 5 and 6. Upon hitting the limits of the
swiveling movement of the bolt 42, the swinging inward or outward
movements of the leg 26 are likewise limited.

[0049] In various alternative embodiments, the swinging inward and outward
movements of the legs 26 and/or retainer clips 12 may be achieved by the
edge of the block 54 or the block 54 itself engaging the inner wall, or
by the bolt shaft hitting the limits of the elongated slotted opening 48,
or both.

[0050] FIGS. 10-11 is a can assembly with an alternative embodiment
retainer clip 12' shown in FIG. 11. The bent tip has been replaced by a
straight section with a hole 60 in the strut 28, which the installer or
electrician can use to hook with the tip of a screwdriver. With the
screwdriver tip inserted into the hole 60, the deployed leg 26 can be
retracted, against the bias from the coiled spring 44, to be retracted
generally flush against the outer wall of the can housing 52.

[0051] FIGS. 12 and 13 are a side elevational and perspective views of the
can housing 52 in the exemplary embodiment shown in FIGS. 7-9 described
above. Other slots and ports may be included in the housing 52 as shown
for ventilation and cooling of the light source, to receive more
electrical wiring, to mount lighting fixture hardware, or to receive
fasteners. Slotted opening 48 may have the hooked keyhole shape with the
enlarged opening at one end to facilitate assembly of the bolt 42 thereto
without removing the bolt from the mounting tab 30. Inverted T-shaped
upper slot 46 further enables assembly, and the wider T area allows for
easy assembly of the spring clip 12 to the can housing 52 by allowing
portions of the strut or distal tip of the strut to pass through if
necessary. FIGS. 14(a)-14(f) are various views of the can housing 52 from
FIGS. 12-13.

[0052] FIGS. 15-17 show a recessed can assembly housing 52 using yet
another alternative embodiment retainer clip 12''. This embodiment has a
bent distal tip 62 that bends the distal end upward toward the top wall,
with a curled hook 64 that bends back downward toward the open bottom.
Because the open bottom of the can housing 52 is where the installer
reaches up into the can housing, the curled hook 64 gives the installer
easy gripping or pressure points for thumb/finger manipulation to retract
the legs 26 and to push the retainer clip 12'' upward against the bias of
the coiled spring. FIGS. 17(a)-17(d) are different views of the retainer
clip 12'' only.

[0053] Unless otherwise described herein, conventional materials and
manufacturing methods may be used to make the present invention.
Additionally, various modifications may be made to the present invention
without departing from the scope thereof. Although individual features of
embodiments of the invention may be shown in some of the drawings and not
in others, those skilled in the art will recognize that individual
features of one embodiment of the invention can be combined with any or
all of the features of another embodiment.